Flowable coating composition



Patented Feb. 27, 1934 UNITED STATES PATENT N0 Drawing. ApplicationJanuary 22, 1931 Serial No. 510,509

9 Claims.

This invention relates to compositions of matter, such as binders andcements and more particularly to a bituminous binder which is useful formany purposes among which may be mentioned the lamination or building upof sheet material employed for building purposes. It is also useful as adeadening composition for deadening sound vibrations in relatively largeexpanses of metal such as in automobile bodies, theater seats,ventilating systems and the like, as described in my copendingapplication Serial No. 36 l,0 l6 filed May 18, 1929, issued as PatentNo. 1,914,912.

The so-called building or plaster board and analogous sheeting ofpresent manufacture takes many forms. Some of such sheeting consistsmerely of fibrous pulp formed as a sheet of convenient size, possiblyone fourth of an inch thick; some manufacturers reinforce this bycementing tough paper, such as kraft paper, to each surface of thesheeting, while still others place a waterproofing coating thereon. Somebuilding board is constructed by forming a large sheet of plaster ormineral cement reinforcing it with fiber board or paper cemented uponeach side.

There has recently been developed a building board of wide application,which building board has been made possible by and includes myinvention. This building board is constructed by binding or laminatingtogether a sheet of fiber board and a sheet of Portland or similar typeof cement, preferably reinforced by fibers, the lamination beingeffected by the use of my novel binder and taking place preferablywhilethe Portland cement sheet is in a moist, plastic, unset condition. Abuilding board results which is not only useful for inside partitions ofbuildings (as in the case of the other building board above mentioned),but which may be used as siding for buildings or shingles for roofs orsimilar uses wherein a permanent sheeting which will resist the elementsis desired.

It is, therefore, among the objects of my invention to provide acomposition of matter which is useful for many purposes requiring astrong cementitious action but which is particularly useful in uniting afibrous structure and wet plastic mass or for sound deadening purposes.Other objects will appear from a further perusal of this specification.

Broadly, my composition comprises merely asphalt, a solvent for theasphalt, and talcousagalite, together with a fiber such as asbestos.Although compositions of matter containing these elements have beenpreviously compounded,

my invention surpasses all such known compositions in that it comprisesmore specifically a mixture of selected asphalts with which isincorporated with the requisite special conditioning, a suitable solventtogether with a tempering agent particularly appropriate for this typeof composition. The talcous-agalite, together with fiber is thenincorporated in this solution.

As an example of my invention, but by which I shall not, of course, belimited except as indicated by the claims appended hereto, the followingis illustrativeof the manner in which my novel binder is prepared. Anasphalt mixture is first prepared by digesting in a steam jacketedmixing kettle approximately eleven parts, by weight, of gilsoniteasphalt having a melting point of about 275 F., about twenty-three partsof petroleum asphalt having a melting point of approximately 190-200 F.,about two parts of raw linseed oil, and approximately thirty-four tothirty-five parts of ordinary varnish makers and painters naphtha havingan initial boiling or distillation point of about 190 F. From this itwill be observed that the ratio of the petroleum asphalt to gilsoniteasphalt is approximately two to one, and that the naphtha added isapproximately equal to the total weight of asphalt.

The use of naphtha, or similar low-boiling, quick-evaporatinghydrocarbon solvent in my composition is significant as it is by the usethereof that exceptional adhesive properties are obtained.

The naphtha above referred to may be either petroleum naphtha or coaltar naphtha. Other hydrocarbon solvents of this type which may beemployed are low-boiling petroleum distillate, benzine, benzol, toluol,and the like.

The foregoing ingredients are well mixed and digested at a temperatureslightly below the boiling point of the naphtha in order that there willnot be too great evaporation of the naphtha. A temperature ofapproximately 185. F. has been found satisfactory. Obviously the mixingkettle is provided with adequate stirring means and is closed except fora small vent which is preferably provided with a condenser forrecovering any vapors issuing from the mixer, which may thus be saved orreturned to the batch, all as will be apparent to those skilled in thisart. The time of mixing is somewhat variable, according to temperature,speed of stirring, etc., although it may be stated that with mildstirring a digesting and mixing time of one to four hours at about 185F. is adequate.

The asphaltic solution so prepared may then be drawn off and filtered orstrained into an open type mixer and into it is then thoroughlyincorporated approximately fifteen parts, by weight, of long fiberasbebstos (such as the Canadian variety) and fifteen parts oftalcous-agalite After sufiicient stirring to permit thorough penetrationof the asbestos and talcous-agilite by the asphaltic solution, thebinder is thus compIeted.

The talcous-agalite above referred to, and which I employ in mycomposition, is a talcous mineral, well known to minerologists. It islargely composed of silicate of magnesia; the largest deposits thereofoccur in northern New York in St. Lawrence County. It has been mined inthat locality and sold for forty years under the registered trade-markAsbestine, usually in the form of an impalpable powder. A representativesample thereof, has the following analysis:

Per cent Silica 61 Magnesia 31 Lime (combined with silica) 4 Water (incrystallization) 4 It is not to be confused with asbestos, which is of afibrous character, nor with ground asbestos (sometimes loosely referredto in the trade as Asbestine), which likewise is of a fibrous character.

While it might at first be thought that the above composition wouldsolidify upon cooling, the reverse is actually true, i. e. thecomposition remains fiowable at all ordinary atmospheric temperaturesand, it is found, can actually be sprayed with the ordinary type of airpressure spray gun so commonly employed in painting and lacquering.While asphaltic solutions are ordinarily quite viscous and sticky, Ihave found that the sprayability of my binder is actually due to thepresence of the asbestos and talcousagalite or to the talcous-agalitealone which gives the requisite slip to the binder to pass through thespray gun. The asbestos in my binder seems to have another importantfunction in that when employed to bind layers of material containingmoisture, the asbestos seems to make the water compatible with thebinder in a way which permits the binder to exert its tenacity toward asheet even though the latter contains a considerable percentage ofwater; doubtless, the talcous-agalite also contributes something in thisregard as it seems to possess even more absorptive qualities than theasbestos; it also adds body to the composition. This is indeedremarkable, as water is ordinarily not compatible with asphalticsolutions except when forming an emulsionwhich obviously does not occurhere. The asbestos also knits the binder together upon drying orhardening thereof.

The gilsonite asphalt toughens the composition, whereas the petroleumasphalt gives it the requisite body to withstandthe higher atmospherictemperatures following evaporation of the naphtha from the binder uponuse thereof, By proportioning these two asphalts as I have, I am able toobtain a binder of great utility. The value of the raw linseed oil in mybinder is also not to be overlooked. By digesting the asphalts in theraw linseed oil, the asphalts are thus tempered so that embrittlement ofthe asphalts upon hardening of the binder is avoided. The presence ofthe linseed oil in the binder also seems to have a plasticizing effectupon the binder so as to induce flexibility, tenacity, and tensilestrength to the hardened binder.

In the preparation of the building board above described the fiber boardis laid upon a press and my binder is coated thereon to a thickness ofapproximately one sixteenth of an inch. It may be either sprayed on orspread on with a trowel, brush or the like. A damp and plastic sheetcomposed of Portland or similar cement, water and and some form offiber, of the desired thickness is then laid upon the binder. A steelsheet separates these sheets from further laminations which are built upso that a pile three or four feet high results. This pile is thenpressed at several hundred pounds pressuresay 500 pounds per squareinch-and permitted to stand at that pressure until the Portland cementhas taken an initial set. One hour is about sufiicient. Upon removal ofthe pressure, the resulting boards may be oven cured or permitted tocure in stacks in ordinary atmosphere for a while.

When the sheet has cured, it will be found that the hardened Portlandcement lamination adheres firmly to the fiber sheet and that theresulting building board appears to consist of a homogeneously mergedfiber and cementitious structure which will withstand the ordinaryelements with an unusual degree of excellence. Examination of such boardwill disclose that my binder has so completely merged or coalesced withthe cement lamination that the two are substantially homogeneous, andalso that my binder has penetrated the fibers of the fiber board to anextent sufiicient for it to encase and grip the fibers to tenaciouslyunite the two laminations.

Obviously the cement sheets may be placed upon both sides of the fibersheet by coating my binder upon each side of the fiber sheet andpressing the cement sheet therewith. Furthermore, numerous other usesfor my binder than that described above will occur to those skilled inthe art and the foregoing is to be understood as merely illustrative ofthe uses to which my invention may be put.

In addition, there will also occur to those skilled in the art manyvariations in the proportions of constituents in my binder and themethod of preparing it. For instance, the proportion of petroleumasphalt to gilsonite asphalt may be varied slightly above or below theratio of two to one. The amount of naphtha may be varied somewhat, itbeing obvious that a thicker or thinner binder will result fromdecreasing or increasing, respectively, the amount of naphtha employed.The beneficial effect of the raw linseed oil may also be varied withinreasonable limits by varying the amount of linseed oil employed,although it will be understood that the proportion given results in anexcellent binder and that the ratio of this tempering agent should notbe greatly changed, if the best results are desired. The proportion ofasbestosand of talcous-agalite may also be varied somewhat to make amore or less plastic binder or for some purposes one may even beomitted, although for the purpose described, the asbestos has animportant function, as above mentioned, as does also thetalcous-agalite, the latter giving slip to the composition which permitsit to be sprayed onto the work; if one of these is to be omitted, itwould be preferable to retain the atmospheric temperatures and whichcomprises approximately two parts asphalt, a quantity of naphtha atleast equivalent to the weight of the asphalt, and at least one parttalcous-agalite.

2. A coating composition which is flowable at atmospheric temperaturesand which comprises approximately two parts asphalt, a quantity of alow-boiling, quick-evaporating hydrocarbon solvent for the asphalt atleast equivalent to the weight of the asphalt, and at least one parttalcous-agalite.

3. A coating composition which is flowable at atmospheric temperaturesand which comprises approximately two parts asphalt, a quantity of alow-boiling, quick-evaporating hydrocarbon solvent for the asphalt atleast equivalent to the weight of the asphalt, and at least one part ofa non-fibrous talcous mineral which contains approximately 92 percentsilicate of magnesia and an appreciable percentage of lime.

4. A coating composition which is flowable at atmospheric temperaturesand which comprises approximately two parts asphalt, a quantity ofnaphtha at least equivalent to the Weight of the asphalt, at least onepart talcous-agalite, and at least one part of asbestos.

5. A coating composition which is fiowable at atmospheric temperaturesand which comprises approximately two parts asphalt, a quantity of alow-boiling, quick-evaporating hydrocarbon solvent for the asphalt atleast equivalent to the weight of the asphalt, at least one parttalcousagalite, and at least one part of asbestos.

6. A fiowable coating composition comprising in approximate parts byWeight the following: thirty-four parts asphalt, at least thirty-fourparts naphtha, and at least fifteen parts talcousagalite.

7. A flowable coating composition comprising in approximate parts byweight the following: eleven parts gilsonite asphalt, twenty-three partspetroleum asphalt, two parts linseed oil, thirtyfour parts naphtha,fifteen parts asbestos, and fifteen parts talcous-agalite.

8. A flowable coating composition comprising in approximate parts byWeight the following: eleven parts gilsonite asphalt, having a meltingpoint of about 275 F., twenty-three parts petroleum asphalt, having amelting point of 190-200 F., two parts linseed oil, thirty-four partsnaph--

